Method of moving a print head between a plurality of partitioned chambers in an additive manufacturing system

ABSTRACT

A method of moving a print head between a plurality of partitioned chambers in a 3D printer includes providing the 3D printer having a thermal barrier having an area defined by a length and width, wherein a print head nozzle can be positioned through the thermal barrier along the width or the length and at least two partitioned chambers below the area of the thermal barrier, wherein a first chamber comprises a printing chamber and a second chamber comprises a chamber providing another functionality. The method includes raising the print head in a z direction from the second chamber to above the thermal barrier and moving the print head in a x-y direction from above the second chamber over the partition to a location above the first chamber. The method also includes lowering the print head in the z direction and into the first chamber such that an extrusion port of a nozzle of the print head is proximate a x-y print plane.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is based on and claims the benefit of U.S.Provisional Pat. Application Serial No. 63/295,140, filed Dec. 30, 2021,the content of which is hereby incorporated by reference in itsentirety.

BACKGROUND

The present disclosure relates to additive manufacturing systems for 3Dprinting of parts. In particular, the present disclosure relates to amethod of moving a print head between a plurality of partitionedchambers in an additive manufacturing system. All references disclosedherein are incorporated by reference.

Additive manufacturing, also called 3D printing, is generally a processin which a three-dimensional (3D) part is built by adding material toform a 3D part rather than subtracting material as in traditionalmachining. Using one or more additive manufacturing techniques, athree-dimensional solid part of virtually any shape can be printed froma digital model of the part by an additive manufacturing system,commonly referred to as a 3D printer. A typical additive manufacturingwork flow includes slicing a three-dimensional computer model into thincross sections defining a series of layers, translating the result intotwo-dimensional position data, and transmitting the data to a 3D printerwhich manufactures a three-dimensional structure in an additive buildstyle. Additive manufacturing entails many different approaches to themethod of fabrication, including material extrusion, ink jetting,selective laser sintering, powder/binder jetting, electron-beam melting,electrophotographic imaging, and stereolithographic processes.

In a typical extrusion-based additive manufacturing system (e.g., fuseddeposition modeling systems developed by Stratasys, Inc., Eden Prairie,MN), a 3D part may be printed from a digital representation of theprinted part by extruding a viscous, flowable thermoplastic or filledthermoplastic material from a print head along toolpaths at a controlledextrusion rate. The extruded flow of material is deposited as a sequenceof roads onto a substrate, where it fuses to previously depositedmaterial and solidifies upon a drop in temperature. The print headincludes a liquefier which receives a supply of the thermoplasticmaterial in the form of a flexible filament, and a nozzle tip fordispensing molten material. A filament drive mechanism engages thefilament such as with a drive wheel and a bearing surface, or pair oftoothed-wheels, and feeds the filament into the liquefier where thefilament is heated to a molten pool. The unmelted portion of thefilament essentially fills the diameter of the liquefier tube, providinga plug-flow type pumping action to extrude the molten filament materialfurther downstream in the liquefier, from the tip to print a part, toform a continuous flow or toolpath of resin material. The extrusion rateis unthrottled and is based only on the feed rate of filament into theliquefier, and the filament is advanced at a feed rate calculated toachieve a targeted extrusion rate, such as is disclosed in Comb U.S.Pat. No. 6,547,995.

In a system where the material is deposited in planar layers, theposition of the print head relative to the substrate is incrementedalong an axis (perpendicular to the build plane) after each layer isformed, and the process is then repeated to form a printed partresembling the digital representation. In fabricating printed parts bydepositing layers of a part material, supporting layers or structuresare typically built underneath overhanging portions or in cavities ofprinted parts under construction, which are not supported by the partmaterial itself. A support structure may be built utilizing the samedeposition techniques by which the part material is deposited. A hostcomputer generates additional geometry acting as a support structure forthe overhanging or free-space segments of the printed part being formed.Support material is then deposited pursuant to the generated geometryduring the printing process. The support material adheres to the partmaterial during fabrication and is removable from the completed printedpart when the printing process is complete.

As 3D printers begin to offer or require additional functionalities,there is a need to be able to move the print head beyond the heatedbuild chamber to access them.

SUMMARY

An aspect of the present disclosure is directed to a method of moving aprint head between a plurality of partitioned chambers in a 3D printer.The method includes providing the 3D printer having a thermal barrierhaving an area defined by a length and width, wherein a print headnozzle can be positioned through the thermal barrier along the width orthe length and at least two partitioned chambers below the area of thethermal barrier, wherein a first chamber comprises a printing chamberand a second chamber comprises a chamber providing anotherfunctionality. The method includes raising the print head in a zdirection from the second chamber to above the thermal barrier andmoving the print head in a x-y direction from above the second chamberover the partition to a location above the first chamber. The methodalso includes lowering the print head in the z direction and into thefirst chamber such that an extrusion port of a nozzle of the print headis proximate a x-y print plane.

Another aspect of the present disclosure relates to a method of moving aprint head between a plurality of partitioned chambers in a 3D printer.The method includes providing the 3D printer having a print head movablein x, y and z directions and at least two partitioned chambers below amovement envelop of the print head, wherein a first chamber comprises aprinting chamber and a second chamber comprises a chamber providinganother functionality. The method includes the steps of raising theprint head in a z direction from within the second chamber to above thesecond chamber, moving the print head in a x-y direction from above thesecond chamber over the partition to a location above the first chamber,and lowering the print head in the z direction and into the firstchamber such that an extrusion port of a nozzle of the print head isproximate a x-y print plane.

Another aspect of the present disclosure relates to a method of moving aprint head between a plurality of partitioned chambers in a 3D printer.The method includes providing the 3D printer having a thermal barrierhaving an area defined by a length and width, wherein a print headnozzle can be positioned through the thermal barrier along the width orthe length and at least two partitioned chambers below the area of thethermal barrier, wherein a first chamber comprises a printing chamberand a second chamber comprises a calibration chamber having acalibration chamber with a sensor. The method includes the steps ofmoving the nozzle above the sensor to determine a location of the nozzleon the print head in x, y and z to determine location errors of thenozzle, raising the print head in a z direction from the second chamberto above the thermal barrier. The method includes moving the print headin a x-y direction from above the second chamber over the partition to alocation above the first chamber, and lowering the print head in the zdirection and into the first chamber such that an extrusion port of anozzle of the print head is proximate a x-y print plane.

DEFINITIONS

Unless otherwise specified, the following terms as used herein have themeanings provided below:

Directional orientations such as “above”, “below”, “top”, “bottom”, andthe like are made with reference to a layer-printing direction of a 3Dpart. In the embodiments shown below, the layer-printing direction isthe upward direction along the vertical z-axis. In these embodiments,the terms “above”, “below”, “top”, “bottom”, and the like are based onthe vertical z-axis. However, in embodiments in which the layers of 3Dparts are printed along a different axis, such as along a horizontalx-axis or y-axis, the terms “above”, “below”, “top”, “bottom”, and thelike are relative to the given axis.

The term “providing”, such as for “providing a print head”, when recitedin the claims, is not intended to require any particular delivery orreceipt of the provided item. Rather, the term “providing” is merelyused to recite items that will be referred to in subsequent elements ofthe claim(s), for purposes of clarity and ease of readability.

The terms “about” and “substantially” are used herein with respect tomeasurable values and ranges due to expected variations known to thoseskilled in the art (e.g., limitations and variabilities inmeasurements).

The terms “additive manufacturing system” and “3D printer” refer to asystem that prints, builds, or otherwise produces parts, prototypes, orother 3D items and/or support structures at least in part using anadditive manufacturing technique. The additive manufacturing system maybe a stand-alone 3D printer or a sub-unit of a larger system orproduction line, it may be in a closed environment (e.g., a box unit) orin an open environment, and/or it may include other non-additivemanufacturing features, such as subtractive-manufacturing features,pick-and-place features, two-dimensional printing features, and thelike.

The term “local Z positioner” refers to a print head positionersupported by an x-y gantry and configured to move the print head or aprint head carriage in a z-band of motion along a vertical z-axis,orthogonal to x and y directions of movement of the x-y gantry.

The term “primary Z positioner” refers to a gantry configured to move aprint platen in a vertical z-axis direction, typically between printinglayers of a part.

The term “toolpath(s)” refers to computer-instructed trajectories of atool in an additive manufacturing process, generated according toindividual part geometries. In fused deposition modeling and othermaterial extrusion process, a toolpath is the path of travel for anozzle to deposit beads or roads of material in the build space.Toolpaths may form planar patterns (e.g., toolpaths printedsubstantially in a planar layer slice, typically parallel to a buildsubstrate) or non-planar patterns (e.g., 3D toolpaths printed in freespace or deposited onto a nonsurface).

The term “toolpath plan” or “path plan” refers to a set of generatedtoolpaths for forming a part(s), and may include parameters required toobtain a desired thickness (or “slice height”) and width of depositedbeads or roads of material along the toolpaths.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an extrusion-based 3D printer of thepresent invention having a heated build chamber positioned below a toolchamber.

FIG. 2 is a perspective view of portions of the 3D printer shown in FIG.1 , with portions of the frame or cabinet removed to illustrateseparation of the build and tool chambers and other features in greaterdetail.

FIGS. 3-5 are views of the 3D printer shown in FIG. 1 , illustratingfilament spool cabinets, x-y gantry and local Z positioner features, andan insulator separating the build and tool chambers.

FIG. 5A is a top view of a thermal isolator between the heated chamberand the tool chamber.

FIG. 6 is a perspective view of an x-y head gantry of exemplarydisclosed 3D printers, with the x-y head gantry including a carriagewith a mount and a local Z positioner in accordance with a firstembodiment.

FIG. 7 is a perspective view of an x-y head gantry of exemplarydisclosed 3D printers, with the x-y head gantry including a carriagewith a mount and a local Z positioner in accordance with a secondembodiment.

FIGS. 8-11 are illustrations of another exemplary 3D printer embodiment.

FIG. 12 is a block diagram illustrating a method of building a 3Dobject.

FIGS. 13-15 are illustrations of a printer showing carriage and printhead positions for the steps of the method shown in FIG. 12 .

FIG. 16 is another block diagram illustrating a method of building a 3Dobject.

FIGS. 17-19 are illustrations of the calibration chamber with the printhead positioned therein.

FIG. 20 illustrates portions of a part on a build surface formed fromextruded material using a print head controlled to print along atoolpath including a z component to form interlocked joints.

FIG. 21 is a diagrammatic illustration of a scarf joint formed using aprint head controlled to print along a toolpath including a z component.

FIG. 22 is another diagrammatic illustration of the formation of a scarfjoint in accordance with an exemplary embodiment.

FIG. 23 is a schematic view of another 3D printer having independentlymove local Z positions for control movement of the print heads.

FIG. 24 is a front view of the local Z positioner in a lowered position.

FIG. 25 is a front view of the local Z positioner in a raised position.

DETAILED DESCRIPTION

The present disclosure is directed to 3D printers having a print headcarriage driven by an x-y gantry and carrying a local Z positioner, suchthat one or more print heads are configured to be moved in the x, y andz directions by the print head carriage. In general, a 3D printer usedwith the present invention includes a build chamber, a build platformthat provides a substantially flat build surface within the buildchamber on which to build parts, a z-gantry (“primary z positioner”) forincrementing the build platform in a z-direction as a part isconstructed layer-by-layer, and a tool rack within the operable space ofthe local Z positioner of the printer for holding print heads andoptionally, other build tools for use in constructing the part.Disclosed embodiments include a high performance, linear motor drivenprint head gantry (x-y gantry) and a linear motor “local Z positioner”providing a local Z range of motion of the print head, carried by thelinear motor driven x-y gantry. The local Z positioner is low mass andstiff enough to perform functions such as extruding in non-planartoolpaths, and elevating the print head carriage to reach an overheadhead tool rack for loading and exchanging print heads.

The present disclosure is also directed to 3D printers having a heatedbuild chamber and a separate tool chamber positioned above the heatedbuild chamber. The tool chamber includes the tool rack for holding printheads and optionally, other build tools for use in constructing thepart. The heated build chamber and the tool chamber are separated by aninsulator in a system which allows a nozzle of a print head to extendfrom the tool chamber into the heated build chamber for extrudingmaterial to build the part on the build platform. The primary zpositioner incrementally lowers the build platform within the buildchamber as the part is constructed layer-by-layer.

The present disclosure may be used with any suitable additivemanufacturing system, commonly referred to as a 3D printer. For example,FIGS. 1-5A illustrate a 3D printer 10 having features as discussedabove. FIG. 1 is a perspective view of the 3D printer enclosed incabinets. FIGS. 2-5 are perspective views, side views or top views ofthe 3D printer with portions removed to illustrate internal featuresmore clearly. As shown initially in FIGS. 1 and 2, 3D printer 10includes a build chamber cabinet 12 housing a heated build chamber 16and a tool chamber cabinet 14 housing a separate tool chamber 18, withthe tool chamber positioned on top of the build chamber. The toolchamber 18 houses multiple individually powered tools, in a tool rack22, including selectable print heads 24. The 3D printer 10 includes acalibration chamber 17, where the calibration chamber 17 is thermallyseparated from the heated chamber 16 but adjacent thereto. The toolchamber is unheated to protect the electronic elements of the printheads and gantry controls.

The calibration chamber 17 houses one or more sensors for sensing alocation of a nozzle 25 of the print head 24, for example, an inductivesensor such as eddy current sensor 19 (as best illustrated in FIGS.17-19 ) for finding a known location in x, y, and z of the nozzle 25.Nozzle calibration is done when swapping one print head for another inorder to maintain accuracy in printing. When any kind of tool change isperformed while a part is being printed, offsets between theoreticalnozzle and tip orifice locations and actual nozzle and tip orificelocations may occur when a fixed relationship between the nozzle(s) andthe tip orifice(s) with the part and/or support structures is notmaintained. The eddy current sensor 19 generates highfrequency magneticfields, and when a metallic nozzle is inserted into this magnetic field,the eddy current sensor uses a resulting change in oscillation todetermine displacement of the nozzle from the sensor and thereby cangenerate a map of a tip of the nozzle from which a center of the nozzletip can be derived. Mapping the nozzle tip allows the toolpaths to beadjusted or shifted for the unique location of each nozzle tip orificerelative to the center of the nozzle tip surface so that printing errorsmay be avoided.

The calibration chamber 17 is separated or partitioned from the heatedchamber 16 is and located at a level below the tool chamber 18. Theheated chamber 16 and the calibration chamber 17 are separated from thetool chamber 18 by a thermal barrier that spans the range of motion ofthe print heads 24. The print head 24 can individually access either theheated chamber 16 or the calibration chamber 17 by moving the print head24 over a partition that separates the heated chamber 16 and thecalibration chamber 17.

While two chambers are described and illustrated below the tool chamber,any number of separated or partitioned chambers can be located below thetool chamber and the thermal barrier such that the print head can accessall of the separated or partitioned chambers. By way of non-limitingexample, the 3D printer 10 can include a third chamber that is used topurge the print heads of material when restarting the printing processfor the particular print head. Another chamber can include other sensorssuch as a touch probe sensor or optical sensor use to determine if thereis build up on the nozzle. The separate chamber can also include adevice or mechanism to clean the detected debris from the nozzle. Eachof the chambers can be controlled at ambient, or elevated temperatureconditions as desired.

The 3D printer 10 includes a print head carriage 26 which connects orcouples to a selected tool or print head, with an x-y gantry 28 movingthe carriage 26 and a selected print head in an x-y plane above a buildplane such that the nozzle 25 is within the heated build chamber 16. Thebuild plane is provided with a platen or platen assembly 30 (shown inFIGS. 4-5 ) within the build chamber 16, with the platen 30 being movedin a vertical z direction within the build chamber by a platen gantry32. The tool chamber 18 and heated build chamber 16 are separated by athermal insulator 20, described below in greater detail, which allowsthe carriage 26 to remain within the (unheated) tool chamber 18 whilethe nozzle 25 extends through the thermal insulator 20 into the heatedbuild chamber 16, such that thermal isolation can be maintained betweenthe build environment and the tool chamber 18.

In the exemplary embodiment of 3D printer 10, a print head 24 is shownengaged on a tool mount 27 of the carriage and has an inlet 23 forreceiving a consumable build material and a nozzle 25 for dispensing thebuild material onto the platform in a flowable state. The consumablebuild material is provided to the print head from one or more filamentspools 50 positioned within spool boxes 56 a, 56 b, 56 c and 56 dpositioned on a side of the build chamber, and through filament guidetubes 54 extending from the spool boxes to the print head.

The building material is optionally and preferably in a filament formthat is suitable for use in an extrusion-based additive manufacturing.The building material may be any extrudable material or materialcombinations, including amorphous or semi-crystalline thermoplastics,and thermosets, and may include fillers, chopped fibers, and/or acontinuous fiber reinforcement. For example, appropriate polymersinclude, but are not limited to, acrylonitrile butadiene styrene (ABS),nylon, polyetherimide (PEI), polyaryletherketone (PAEK), polyether etherketone (PEEK), polyactic acid (PLA), Liquid Crystal Polymer, polyamide,polyimide, polysulfone, polytetrafluoroethylene, polyvinylidene, andvarious other thermoplastics.

A fiber-reinforced filament may consist of one or more types ofcontinuous fibers. The continuous fibers may be extended, woven, ornon-woven fibers in random or fixed orientations and may consist of, forexample, carbon fibers, glass fibers, fabric fibers, metallic wires, andoptical fibers. The fiber-reinforced filament may also consist of shortfibers alone or in combination with one or more continuous fibers.Appropriate fibers or strands include those materials which impart adesired property, such as structural, conductive (electrically and/orthermally), insulative (electrically and/or thermally), and/or optical.Further, multiple types of fibers may be used in a singlefiber-reinforced filament to provide multiple functionalities such aselectrical and optical properties.

As shown, the x-y gantry 28 is mounted on top of the build chamber, andin an exemplary embodiment comprises an x-bridge 60, y-rails 52, andassociated x and y motors for moving and positioning the carriage 26(and any build tool installed on the carriage) in an x-y plane above thebuild plane. The carriage is supported on the x-bridge and includes amount 27 for receiving and retaining print heads and a local Zpositioner 72 for controllably moving a retained print head out of thex-y build plane along a perpendicular z direction axis (e.g., not in apivoting manner). The local Z positioner operates to move a retainedprint head in a limited Z band of motion from a build position to a toolchange position. Additionally, in some embodiments may be utilized whilethe carriage is moving in x-y or when it is in a fixed x-y position. Thex-y gantry, as well as the local Z positioner, can utilize any suitablemotors, actuators or systems to move the carriage and print head in thex, y and z directions as discussed.

The local Z positioner also operates to move a newly retained print headover the tool chamber and into a calibration chamber 17 separate fromthe heated chamber 16 and tool chamber 18. The calibration chamber 17includes the sensor 19 configured to calibrate a location of a nozzletip surface 25 on the print head 24 in x, y and z. Once the print headis over the calibration chamber 17, the print head is lowered into thecalibration chamber 17 proximate the sensor to sense the location of thenozzle tip surface 25.

Tool crib or rack 22 is located above the build chamber at a positionreachable by the tool mount 27 when elevated by the local Z positioner72. The tool mount may engage with and support a print head, and is usedto retain and swap print heads provided in the rack. In general, anymodular tools, such as print heads or any other tools (generally andcollectively referred to below simply as “tools”) that are removably andreplaceably connectable to a 3D printer may be stored in bins of a toolrack for managing tool inventory and interchanging tools duringoperation of the 3D printer. The local Z positioner 72 is utilized forpicking and placing tools in the bins so that the 3D printer caninterchangeably use the various modular tools contained in the toolrack. The tool rack may be any suitable combination of containers orother defined spaces for receiving and storing tools.

3D printer 10 also includes controller assembly 38, which may includeone or more control circuits (e.g., controller 40) and/or one or morehost computers (e.g., computer 42) configured to monitor and operate thecomponents of 3D printer 10. For example, one or more of the controlfunctions performed by controller assembly 38, such as performing movecompiler functions, can be implemented in hardware, software, firmware,and the like, or a combination thereof; and may include computer-basedhardware, such as data storage devices, processors, memory modules, andthe like, which may be external and/or internal to system 10.

Controller assembly 38 may communicate over communication line 44 withprint head 24, filament drive mechanisms, chamber 16 (e.g., with aheating unit for chamber 16), head carriage 26, motors for platen gantry32 and x-y or head gantry 28, motors for local Z positioner 72, andvarious sensors, calibration devices, display devices, and/or user inputdevices. In some embodiments, controller assembly 38 may alsocommunicate with one or more of platen assembly 30, platen gantry 32,x-y or head gantry 28, and any other suitable component of 3D printer10. While illustrated as a single signal line, communication line 44 mayinclude one or more electrical, optical, and/or wireless signal lines,which may be external and/or internal to 3D printer 10, allowingcontroller assembly 38 to communicate with various components of 3Dprinter 10.

During operation, controller assembly 38 may direct platen gantry 32 tomove platen assembly 30 to a predetermined z-height within chamber 16,moving it in increments which represent the height of an individual partslice, typically 0.0050 - 0.020 inches in z-height . Controller assembly38 may then direct x-y gantry 28 to move head carriage 26 (and theretained print head 24) around in the horizontal x-y plane above chamber16, and direct the local Z positioner 72 to move the head carriage insmaller, or larger, incremental movements within the z directionrelative to the x-y plane, in addition to the platen gantry z movement.Controller assembly 38 may also direct a retained print head 24 toselectively advance successive segments of the consumable filaments fromconsumable spools 50 through guide tubes 54 and into the print head 24.It should be noted that movements commanded by the controller assembly38 may be directed serially or in parallel. That is, the print head 24can be controlled to move along the x, y and z axes by simultaneousdirecting the x-y gantry 28 and the local Z positioner 72 to re-positionthe head carriage 26 along each axis.

At the start of a build process, the build plane is typically at a topsurface of the build platform or platen 30 (or a top surface of a buildsubstrate mounted to the platen) as shown in FIG. 4 , where the buildplatform is positioned to receive an extruded material from the nozzle25 of the print head. A top surface of the sensor 19 and calibrationblock 632 in the calibration chamber 17 is substantially aligned withthe top surface of the build platform or platen 30 as the print processis started such that the x, y and z positions of the nozzle 25 can besensed in a z location that is aligned with the build plane during theprinting of the part and associated support structure.

As layers are built, the platen is indexed away from the build plane,allowing printing of a next layer in the build plane. The platen gantry32, or primary Z positioner, moves the build platform away from theprint plane in between the printing of layers of a 3D fabricated part 74(shown in FIG. 5 ). One or more parts and associated support structurescan be printed in a layer-by-layer manner by incrementally lowering theplaten in the z direction. FIG. 5 illustrates portions of 3D printer 10with the platen 30 at a lowered position, achieved through numerousincremental z direction repositioning steps while printing.

As discussed, the build chamber 16 of the 3D printer typically is heatedto provide a heated or ovenized build environment, such as in the caseof FDM® 3D printers manufactured and sold by Stratasys, Inc. of EdenPrairie, MN. The heated build chamber is provided to mitigate thermalstresses and other difficulties that arise from the thermal expansionand contraction of layered build materials during fabrication, usingmethods such as are disclosed in U.S. Pat. No. 5,866,058. The insulator20 shown in FIGS. 2-5 is a deformable or movable thermal insulatorcomprising pleated bellows which allows the x-y gantry to move the headcarriage 26 and attached print head 24 to move in the x-y plane. Anexample of a deformable thermal insulator 20 which allows the x-y planemovement is disclosed in Stratasys U.S. Pat. No. 7,297,304, utilizing apleated bellows in the x direction and another in the y direction. Aroller style insulator or insulators may also be used, in place of apleated bellows or in combination therewith. In the shown embodiment, athermal insulator tray 84 or similar mechanism is provided betweensections of the deformable insulator 20 to provide access for the nozzle25 of the print head into the heated build chamber while aiding ininsulating the build chamber from the tool chamber. The thermalinsulator tray 84 allows the print head to move in the y-direction asthe x-y gantry 28 moves the head carriage, and the sections ofdeformable thermal insulator 20 on either side of the thermal insulatortray move or deform as the head carriage is moved in the y-direction, tomaintain the thermal insulation between chambers.

As discussed above, some embodiments of the present disclosure aredirected to 3D printers having a print head carriage driven by an x-ygantry, with the print head carriage carrying a local Z positioner. Thisallows a print head or other tool carried by the print head carriage tobe moved in the x, y and z directions by the print head carriage.Further, the x-y gantry and local Z positioner allow the tool mount ofthe carriage to be raised within the tool chamber to positions adjacentthe tool rack to couple to a variety of individual print heads or tools.Further, the x-y gantry and local Z allows the print head to be movedbeyond the print envelope of the heated chamber and above the separatecalibration chamber 17 and lowered into the calibration chamber 17 suchthat the position of the nozzle 25 of the print head 24 can bedetermined in x, y and z by the sensor prior to restarting the printingafter a tool change. The local Z positioner also allows the headcarriage and tool mount to be lowered to positions with the nozzle of aprint head extending into the heated build chamber while the remainderof the print head remains in the tool chamber.

Referring now to FIG. 6 , an example embodiment of an x-y gantry and alocal Z positioner, which can serve as x-y gantry 28 and local Zpositioner 72, are provided. The x-y gantry 128 shown in FIG. 6 ismounted on top of the build chamber (as shown in FIGS. 2-5 ), andincludes an x-bridge 160, y-rails 152, and associated x and y motors 168and 156 for moving and positioning a head carriage 126 and any buildtool (e.g., a print head, subtractive head, instrumentation anddetection devices) installed on the carriage in an x-y plane above thebuild plane. In exemplary embodiments, x and y motors 168 and 156 arelinear motors, though other motors can be used in alternate embodiments.The carriage 126 is supported on the x-bridge 160 and includes a toolmount 127 for receiving and retaining print heads, and a local Zpositioner 172 configured to controllably move a retained print head outof the x-y build plane along a perpendicular z direction axis (e.g., notin a pivoting manner). The local Z positioner 172 operates to move theprint head in a limited z band of motion, and may be utilized while thecarriage is moving in x-y or when it is in a fixed x-y position. Inexemplary embodiments, the local Z positioner 172 utilizes a linearmotor which allows the 3D printer to move the print head in the zdirection while extruding build material from the print head. This inturn allows x, y and z movement of the print head to implement atoolpath, with the z movement of the print head allowing relativelysmall print head excursions in the z direction while printing in the x-yplane.

Local z positioner 172 includes a local Z bridge 174 which is moved inthe x direction along the x-bridge 160 by one or more x linear motors168. In this embodiment, the x-bridge extends 160 through the local Zbridge structure. The local Z bridge 174 includes or supports headcarriage 126 having mount 127 and local Z positioner 172. Local z linearmotor 176 of the local Z positioner moves the mount 127 and any attachedprint head 24 up and down in the z direction, perpendicular to the x-yplane of the build surface. Also as shown in FIG. 6 , a thermalinsulator tray 184 includes overlapping straps 183 and 185 secured onthree sides to the x-bridge 160 and having free edges 187 that define aslot or central portion 188 through which a portion of nozzle 25 (andoptionally other print head components such as a portions of a printhead liquefier) of the retained print head 24 is inserted into, andextend into the build chamber of the printer when printing. As shown forexample in FIGS. 2, 4, 5 and 5A an insulator 20, such as an insulatingbaffle, connects to both sides of thermal insulator tray 184 and forms aceiling of the heated build chamber 16, the calibration chamber 17 andany other chamber(s) as needed, and the nozzle 25 of the engaged printhead 24 extends through the slot or central portion 188 (via the thermalinsulator tray 184) into the build chamber when the engaged print headis in the build position, into the calibration chamber when calibratinga nozzle of a newly swapped print head or any other chamber havingdifferent functionalities. The nozzle of the engaged print head is abovethe insulator or baffle when the engaged print head is in a toolexchange position where the insulator or baffle spans all of thepartitioned chambers of the 3D printer. As the tool changer moves aboveand over the thermal insulator area within the tool chamber, the thermalinsulator opening or slit access point moves with the print head andcarriage, to allow an entry point into either the headed build chamberor the calibration chamber. By maintaining only a small slit area withan opening between the heated and unheated portion of the printer, lessheat escapes into the tool chamber while still allowing a high level ofaccessibility to either area, and the sensitive electronics of the toolchanger and gantry are kept cool in the unheated tool chamber.

In the embodiment shown in FIG. 6 , the x-bridge is in a stackedarrangement positioned above the baffle and at a higher z elevation thanthe thermal insulator tray 184. Also in this embodiment, the local Zbridge 174 which forms or supports the head carriage has an opening suchthat the x-bridge 160 extends through the local Z bridge.

As will be discussed further, the local Z positioner can utilize a localZ linear motor to provide a local z direction range of motion of themount 127 of carriage 126 to be raised to a position proximate a toolrack (e.g., tool rack 22 shown in FIGS. 2-5 ) to retrieve, return orexchange print heads or other tools. The provided range of motion in thelocal z direction also allows the print heads to be lowered such thattips of nozzles 25 are in position against or proximate the buildsurface within chamber 16 for advanced printing techniques, or forcalibration and monitoring of the platen position, the x-y gantry, thelocal Z positioner, or other components and system and/or to bepositioned within the calibration chamber 17 for determining thelocation of the nozzle on a print head being placed into service.

Referring now to FIG. 7 , another example embodiment of an x-y gantryand a local Z positioner, which can serve as x-y gantry 28 and local Zpositioner 72, are provided. In this embodiment, the x-y gantry 228again includes an x-bridge 260, y-rails 252, and associated x and ymotors 268 and 256 for moving and positioning a local Z bridge 274 whichincludes or provides the head carriage 226. Again, in exemplaryembodiments, x and y motors 268 and 256 are linear motors, though othermotors can be used in alternate embodiments. The carriage 226 of local Zbridge 274 is supported on the x-bridge 260 and includes a tool mount227 for receiving and retaining print heads, and a local Z positioner272 configured to controllably move a retained print head out of the x-ybuild plane along a perpendicular z direction axis. Like local Zpositioner 172, local Z positioner 272 operates to move the carriage ina limited z band of motion, and may be utilized while the carriage ismoving in x-y or when it is in a fixed x-y position. In exemplaryembodiments, the local Z positioner 272 utilizes a linear motor 276which allows the 3D printer to move the print head in the z directionwhile simultaneously extruding build material from the print head toprint a part. This in turn allows x, y and z movement of the print headto implement a multi-z height toolpath, with the z movement of the printhead allowing relatively small print head excursions in the z directionwhile printing in the x-y plane.

Also as shown in FIG. 7 , a thermal insulator tray 284 includesoverlapping straps 283 secured on three sides to the x-bridge 260 andhaving free edges that define a slot or central portion 288 throughwhich a portion of nozzle 25 of the retained print head 24 is insertedinto, and extend into the build chamber of the printer when printing.Similarly, the thermal insulator tray 284 extends above the calibrationchamber 17 so that a nozzle can be lowered into the calibration chamber17 at a selected distance above the sensor to determine the location ofthe nozzle of a newly swapped print head in x, y and z to minimizeprinting errors. Like thermal insulator tray 184, thermal insulator tray284 is configured to have an insulator 20, such as an insulating baffle,connected to form a ceiling of the heated build chamber, and the nozzle25 of the engaged print head 24 extends through the baffle (via thethermal insulator tray 284) into the build chamber when the engagedprint head is in the build position. In this embodiment, the x-bridge260 is adjacent, instead of above, the thermal insulator tray 284 toform part of the seal structure. The insulating baffle is then coupledto one side of the thermal insulator tray 284 and to the distant side ofthe x-bridge to form the insulated ceiling of the heated build chamber.Also, in this embodiment, in order to reduce the effects of anyrotational movement at the x-linear motor bearing on the degree ofdisplacement at the tip of the mount 227, instead of extending thex-bridge through the local Z bridge structure, the x-linear motor 268(e.g., magnets, rails) and the structure of the local Z bridge 274 arepositioned on top of the x-bridge 260B. This configuration reduces thetip deflection effects of torque or rotation.

In exemplary embodiments utilizing x, y and z linear motors, the linearmotors provide a high-performance print head gantry (x-y gantry) and“local Z” positioner. The local Z positioner is of low mass and stiffenough to perform functions such as extruding in non-planar toolpaths,and elevating the print head carriage to reach an overhead head toolrack for loading and exchanging print heads while maintaining positionalaccuracy at the build layer location. For example, with an extruderprint head weight of less than 2.5 lbs. and a linear z motor weight ofapproximately 1.3 lbs., a total local Z positioner mass of onlyapproximately 14 lbs. (including a magnet track, bearings, structure,encoder, energy chain, etc.) can be achieved. With a zero hysteresis andhigh acceleration linear motor, and with low friction, this allows highspeed precision control of the print head, and thus, highly accuratetoolpath deposition placement.

Consistent print head tip location is mandatory in order to createaccurately printed parts. If the tip location varies, the part geometrywill not be accurate. Each time that print head is swapped from the toolchanger, the potential for print head tip location variation isintroduced, because the print head might be in a slightly differentposition, or some type of positional hysteresis may have occurred, orbecause each print head is microscopically different in size. Becauseslice heights can be as small as 0.5 mm, small variations lead toprinted part errors or failures if not accommodated for. The local zpositioner allows for a consistent and precise way of maintaining printhead tip position, while also providing a high level of accuracy forlocal z movements beyond the typical movement of the primary z platengantry. Because of that precise and accurate locational control, twoperformance functions are enabled - 1) printing an individual part usingmore than one particular print head during the build, and 2) extrudingmaterial to print a particular part layer while moving the print headheight in z. Both of these functions are typically require very accurateand precise knowledge and control of the print head tip location.

In exemplary embodiments, the local Z linear motor provides the abilityto make micrometer-scale movements of the print head, up and down in thez direction, beyond the platen gantry (primary) z movement location,without any hysteresis using integral one micrometer (1 µm) scalefeedback. For example, using a linear encoder with a 1 micronresolution, sub-four micrometer movements can be made with 3 microns offollowing error. This feedback, along with the linear motor with lowfriction, allows for precision control of the print head tip location.Having no (zero) compliance between the feedback device and the movingmass of the print head and carriage is an advantage provided by the useof linear motors. Using the disclosed embodiments, there is no need toaccount for lost motion or compliance between a static motor and an endeffector, for example as produced by ball screws, belts, etc. Theprecise positioning and feedback provided by the local Z linear motorfacilitates highly accurate toolpath control with small excursions inthe z direction, as well as calibration, monitoring and control ofcomponents and systems of disclosed printers such as 3D printer 10. Forexample, the capability to move local Z height within a toolpath layerwhile extruding material for a printed layer enables an ability tocreate overlapped start and end joint seams, sometimes referred to asscarf seams, instead of creating abutted end joints. Such seams provideadditional layerwise strength to built parts. Scarf seams also providethe potential to greatly reduce any potential bulging of the width ofthe overall seam region, which can otherwise create shape variation in apart. In addition, using the x, y and local Z linear motors providesprecise tip position information. The local z unit allows for print headtip location calibration activities - to sense contact with the buildsurface facilitates calibration of the platen and system, by allowingthe controller assembly 38 (shown in FIG. 1 and included in alldisclosed 3D printer embodiments) to locate or determine the zeroposition for the platen gantry and platen; also, the local z unit can beused to monitor upward forces on the nozzle tips while printing todetect overfill and curl, etc. As linear motors can be back driven byloads or forces on the tip of the print head nozzle, the loads can besensed by controller assembly 38 and the print head and local Z linearmotor can be used as a touch probe to measure set platen level, or othersystem parameters.

Referring now to FIGS. 8-11 , shown is another 3D printer embodimenthaving certain features as discussed above. The 3D printer 400 isillustrated with various components, such as some or all of the framesor cabinets 412 housing the heated build chamber 416 and tool chamber418, removed to allow more detailed illustration of x-y gantry, local Zpositioner and tool change features. These features, and others suchcontroller 38 or various features shown in FIGS. 1-5A illustrating 3Dprinter 10, can also be included in 3D printer 400 and the presentdisclosure should be understood to disclose such features with referenceto 3D printer 400.

As shown partially in FIGS. 8, 3D printer 400 includes system cabinet orframe 412 providing a heatable chamber 416 in which a platen 430 of aplaten system is positioned to provide a build surface 431. The buildplane of surface 431 lies in a substantially horizontal x-y plane, andthe platen 430 is moved in a z direction substantially normal to thesubstantially horizontal x-y build plane by one or more actuators 434 ofa platen gantry 432 (primary z positioner). In FIG. 8 , platen 430 andbuild surface 431 are shown in a lowered position for illustrativepurposes, but with print head 24 in a lowered position for printingwithin the heated build chamber 416 as discussed below, the platengantry 432 will ordinarily have the platen and build surface raised suchthat a top layer of a part being fabricated is positioned to allownozzle 25 of the print head to extrude a next layer onto the part.

In this particular embodiment, 3D printer 400 includes the x-y gantry128 (shown in FIG. 6 ) positioned on top of the build chamber 416, withinsulator 420 positioned between the tool chamber 418 (shown without aframe or cabinet for illustrative purposes). As such, x-y gantry 128 of3D printer 400 includes an x-bridge 160, y-rails 152 (shown in FIGS.9-10 which have insulator 420 removed for illustrative purposes).Associated x and y motors 168 and 156 shown in FIG. 9 move and positionhead carriage 126 and any build tool (e.g., a print head, subtractivehead, instrumentation and detection devices) installed on the carriagein an x-y plane above the build plane. In exemplary embodiments, the xand y motors are linear motors as discussed further below. The carriage126 is supported on the x-bridge 160 and includes tool mount 127 forreceiving and retaining print heads, and local Z positioner 172configured to controllably move a retained print head out of the x-ybuild plane along a perpendicular z direction axis (e.g., not in apivoting manner). The local Z positioner 172 operates to move thecarriage in a limited z band of motion, and may be utilized while thecarriage is moving in x-y or when it is in a fixed x-y position. Inexemplary embodiments, the local Z positioner 172 utilizes a linearmotor which allows the 3D printer to move the print head in the zdirection while extruding build material from the print head. This inturn allows x, y and z movement of the print head to implement atoolpath, with the z movement of the print head allowing relativelysmall print head excursions in the z direction while printing in the x-yplane.

Local Z positioner 172 includes local Z bridge 174 which is moved in thex direction along the x-bridge 160 by one or more x linear motors asdiscussed above. The local Z bridge 174 includes or supports headcarriage 126 having mount 127. Linear motor 176 of the local Zpositioner moves the mount 127 and any attached print head 24 up anddown in the z direction, perpendicular to the x-y plane of the buildsurface.

As shown in FIG. 8 , thermal insulator tray 184 discussed above withreference to FIG. 6 includes a slot or central portion through which aportion of nozzle 25 (and optionally other print head components such asa portions of a print head liquefier) of the retained print head 24 isinserted into the build chamber of the printer when printing or insertedinto the calibration chamber 17 and above the sensor after a print headis swapped into service. Insulator 420, such as an insulating baffle,connects to both sides of thermal insulator tray 184 and forms a ceilingof the heated build chamber 416, the calibration chamber 17 and anyadditional partitioned chambers that provide different functionalitiesand the nozzle 25 of the engaged print head 24 extends through thebaffle (via the thermal insulator tray 184) into the build chamber whenthe engaged print head is in the build position. As shown in FIG. 11 ,the nozzle of the engaged print head is above the insulator or bafflewhen the engaged print head is in a tool exchange position.

At the start of a build process, the build plane is typically at a topsurface of the build platform provided by platen 430 (or a top surfaceof a build substrate mounted to the build platform), where the buildplatform is positioned to receive an extruded material from the nozzle25 of the print head 24. The top surface of the sensor in thecalibration chamber 17 is substantially aligned with the top surface ofthe build platform at the start of the build process. As layers arebuilt, the platen 430 is indexed away from the build plane by the platengantry or primary Z positioner 432, allowing printing of a next layer inthe build plane. The primary Z positioner moves the build platform awayfrom the print plane between layers (while printing is paused). Thisincrementing creates the height of the next print layer, or slice.

Alternatively, in some embodiments, at the start of a build process, theprimary Z positioner positions the platen at an initial position lowerthan a nominal build plane, and the local Z positioner positions thenozzle of the print head to print near the bottom of the local Zpositioner stroke range. This allows the primary Z position of theplaten to be started at a lower height. Once the local Z print positionreaches and prints at its nominal build height, the primary Z positionerbegins to move the platen down by the height of a slice or layer, withthe print head printing at the local Z nominal build height, during theremainder of the build. Some advantages of this process include that itprevents, or reduces, the platen from blocking airflow from the ovenexhaust, while giving the user and any monitoring camera system a betterview of the part start since the platen is lower and out of the way.

The print heads 24 are removably coupled to carriage 126 by mount127,and have an inlet 23 for receiving a consumable build materialthrough filament guide tubes 454. Only a portion of filament guide tubesare shown in FIG. 8 , but it should be understood that the guide tubescan extend from the filament supply (e.g., spools mounted to a spindle,spool boxes, canisters, cartridges, etc.) to the print head, asdiscussed with reference to 3D printer 10. Although not illustrated indetail, those of skill in the art will understand that print heads 24can include a liquefier which provides the nozzle 25 for dispensing thebuild material onto the build surface or platform in a flowable state.Those skilled in the art will also recognize that other types ofconsumable supplies and other form factors of consumables may beutilized in practicing the inventions disclosed herein, includingwithout limitation pellets feeding a print head that utilizes a screwextruder such as disclosed in Stratasys (Bosveld) U.S. Pat. No.8,955,558, and with or without the use of guide tubes.

In FIGS. 8-11 , multiple print heads are shown positioned in bins 423 ofa tool crib or tool rack 422, of a tool changer system 404, configuredto store multiple print heads above the build chamber 416, outside theheated region. Tool changer system 404 and tool rack 422 can be anysuitable system and tool storage structure, for example such as the toolchanger systems and structures disclosed in U.S. Pat. Nos. 7,625,198;7,939,003; 9,481,132; 9,469,072 and 10,214,004, which are hereinincorporated by reference in their entirety. In exemplary embodiments,each of the multiple print heads includes a tool connector 490 (shown inFIG. 10 ) configured to connect and disconnect with tool mount 127 oncarriage 126 in response to commands from the controller. A robotic toolchanger having two mating parts may be utilized for the tool connectors490 and tool mount 127, for example a tool-side and master-sideend-effector in the QC-7 Series sold by ATI Industrial Automation ofNorth Carolina and designed to lock together automatically, carry apayload, and pass utilities such as electrical signals. Each of thetools in the tool crib 422 are electrified, making them able to performactivities or communication functions at all times.

As will be discussed further, the local Z positioner 172 utilizes thelocal Z linear motor 176 to provide a local z direction range of motionof the mount 127 of carriage 126 to be raised to a position proximatetool rack 422 to retrieve, return or exchange print heads or other toolsfrom bins 423. FIGS. 9 and 10 illustrate mount 127 in a raised positionand without a print head attached. With the mount raised by the z linearmotor 176, the x linear motor 168 is controlled to position the mount127 in front of the particular bin 423 of tool rack 422 where a printhead 24 or tool to be retrieved is stored. A y linear motor 156 can thenmove the head carriage and mount 127 in the y direction such that mount127 couples to tool connector 490 of the print head. After coupling themount 127 to the print head, the y linear motor moves the head carriageand print head along the y axis and away from the tool rack 422 as shownin FIG. 11 . The provided range of motion in the local z direction alsoallows the print heads to be lowered such that tips of nozzles 25 are inposition against or proximate the build surface within chamber 416 forprinting, or for calibration and monitoring of the platen position, thex-y gantry, the local Z positioner, or other components and system. Theprovided range of motion also allows the print head and nozzle to bepositioned into the separate calibration chamber 17 and above acalibration sensor to determine the position of the nozzle 25 in the x,y and z directions. The print head can also be moved to another chamberor to the heated chamber by moving the print head in the z directionsuch that the tip surface of the print head exits above the partitionand then moved in the x-y direction within the unheated tool chamber toabove another desired chamber, and then lowered into the other chamberthrough the thermal insulator slit entry point, either to print a partor to provide an additional functionality to the print head. Althoughthe platen 430 is shown in a lowered position for illustrative purposes,this lowered print head position is illustrated in FIG. 8 .

In order to allow the z linear motor 176 to rapidly move the headcarriage 126 and any retained print head within the local Z range ofmotion, for fast tool change operations or for movement of the printhead in the z direction while printing, the local Z positioner caninclude features which quickly stop or dampen movement of themount/print head at the upper and/or lower bounds of local Z range ofmotion. As shown in FIGS. 8-11 , a bumper 450 is included on the local Zbridge 174 of local Z positioner 172. Bumper 450 is positioned to becontacted by mount 127 or other components when the local Z linear motormoves the mount to its upper most local Z position. One or more springs452 are positioned on the local Z bridge 174 at a location near thelower most local Z range of motion. When the local Z linear motor ispowered, motor movement can be dampened by the motor itself, through thecontroller and closed loop control (as can be the case with the X and Ymotors). The one or more springs 452 perform this dampening functionwhen the motor power is lost and the motor falls due to gravity. Inembodiments in which a single spring is used, the spring can be longerand start making contact earlier so as to better dampen the load if/whenthe local Z linear motor falls due to power loss or drive fault. Anotherprimary function of the one or more springs 452 is to compensate for themass of the local Z positioner itself, plus the mass of the extruderwhen a print head is attached. Using this technique, there is almost nomotor current required to hold up the mass while printing and as aresult almost all the motor force/current can be used for the printingprocess. As the local Z positioner will typically spend over 90% of itsoperational time in a printing position with the print head printing,the one or more springs 452 also help improve motor life (reduces motortemperature).

Referring now to FIG. 12 , shown is a block diagram illustrating amethod 600 of printing a 3D part using a 3D printer having a heatedbuild chamber, a separate tool chamber, and a thermal insulatorpositioned between the build and tool chambers. The method 514 isdescribed with reference to a printer 500 shown in FIGS. 13-15 . Printer500 includes a build chamber 516, a tool chamber 518 separated from thebuild chamber by an insulator 520, and an x-y gantry 228 and local Zpositioner 272 of the types shown in FIG. 7 . In the side views of FIGS.13-15 , the y motors 256 of the x-y gantry are shown, but the x motors268 are not visible. As discussed above with reference to FIG. 7 , thecarriage 226 has a local Z bridge 274 which includes a tool mount 227which can be moved by a Z motor 276 in a local Z range of motion.

As shown at block 502, method 514 includes using the local Z positionerof the print head carriage to move the tool mount 227 in the z-directionto a tool exchange z position of a bin of a tool rack 522 which retainsa print head in the tool chamber 518. As shown at block 504, the methodalso includes moving the print head carriage, to a first position in anx-y plane within the tool chamber using the x-y gantry, with the firstposition in the x-y plane being adjacent the bin in which the print head24 to be engaged is retained. These steps are represented by the headcarriage position illustrated in FIG. 13 .

Method 514 also includes the step shown at block 506 of engaging theprint head 24 in the bin with the tool mount 227 of the print headcarriage. After the print head has been engaged by the tool mount, theprint head carriage and print head are moved to a second position in thex-y plane as shown at block 508 in FIG. 12 . The results of this stepare represented by the head carriage position illustrated in FIG. 14 .

Method 514 also includes the step shown at block 510 of using the localZ positioner to move the tool mount and engaged print head in the zdirection to a build position at which the nozzle 25 of the engagedprint head extends from the tool chamber 518 through the insulator 520and reaches an x-y build plane within the build chamber. The results ofthis step are represented by the head carriage position illustrated inFIG. 15 . Then, the method includes the step shown at block 512 ofextruding consumable material through the nozzle of the print head andinto the build chamber with the engaged print head at the build positionto build the 3D object. While extruding, the x-y gantry moves the printhead along the desired tool path, and in some embodiments the local Zpositioner 272 concurrently moves the print head comparatively smallerdistances in the z direction, as further described below.

Referring now to FIG. 16 , shown is a block diagram illustrating amethod 601 of printing a 3D part using a 3D printer having a heatedbuild chamber, a separate tool chamber, a separate calibration chamberand an insulator positioned between the build and calibration chambersand tool chambers. The method 601 is described with reference to aprinter 500 shown in FIGS. 13-15 , as described above.

As shown at block 602, method 601 includes using the local Z positionerof the print head carriage to move the tool mount 227 in the z-directionto a tool exchange z position of a bin of a tool rack 522 which retainsa print head in the tool chamber 518. As shown at block 603, the methodalso includes moving the print head carriage, to a first position in anx-y plane within the tool chamber using the x-y gantry, with the firstposition in the x-y plane being adjacent the bin in which the print head24 to be engaged is retained. These steps are represented by the headcarriage position illustrated in FIG. 13 .

Method 601 also includes the step shown at block 604 of engaging theprint head 24 in the bin with the tool mount 227 of the print headcarriage. After the print head has been engaged by the tool mount, theprint head carriage and print head are moved to a second position in thex-y plane as shown at block 605 in FIG. 16 . The results of this stepare represented by the head carriage position illustrated in FIG. 14 .

Method 601 also includes the step shown at block 606 where the nozzle isoptionally heated. Optionally, the local Z positioner can be used tomove the tool mount and engaged print head in the z direction to a buildposition at which the nozzle 25 of the engaged print head extends fromthe tool chamber 518 through the insulator 520 and reaches an x-y buildplane within the build chamber. The results of this step are representedby the head carriage position illustrated in FIG. 15 . Another option isto heat the nozzle while mounted in the tool rack.

After the tip is heated in block 606, the local Z positioner moves theprint head from the tool chamber and into the calibration chamber abovethe sensor in the calibration chamber in block 607. The sensor thensenses the nozzle tip to determine the position of the tip surface in x,y and z such that positioning errors can be identified in block 608. Theprint head and sensor are then returned to the heated chamber at step609 and the method includes the step shown at block 610 of extrudingconsumable material through the nozzle of the print head and into thebuild chamber with the engaged print head to build the 3D object. Whileextruding, the x-y gantry moves the print head along the desiredtoolpath, and in some embodiments the local Z positioner 272concurrently moves the print head comparatively smaller distances in thez direction, as further described below.

The calibration chamber 620 and the sensor 622 are illustrated in FIGS.17-19 . The calibration chamber 620 (17, 517 in FIGS. 1-15 ) is separatefrom the heated chamber 16 and the tool chamber 18. The calibrationchamber 620 can include fans 626 and an exhaust port 628 to activelycool the sensor 622. The temperature of sensor 622 is monitored andmaintained substantially constant utilizing a temperature sensor 623, asthe sensor readings can fluctuate with temperature and will not providean accurate calibration if the sensor temperature is not compensated oris allowed to drift.

The sensor 622 includes a top surface 624 that is substantially alignedwith the top surface of the platen when the platen is positioned toinitiate the start of the build process. A metal z-height calibrationblock 632 is ideally installed within the printer at a location that canallow for identification of the platen height at the beginning of a partbuild, and throughout the build process - known as the z-height of thexy print plane. The sensor 622 in the printer is retained within acavity 630 of the block 632 with a strap 634 that spans the cavity 630and retains the sensor 622 in a fixed location. The mass of the block632 dampens vibrations and aids in retaining the sensor 622 in the fixedlocation within the calibration chamber 620. The block 632 can beconstructed of any suitable material, and is typically metal to providesufficient mass to prevent movement of the sensor 602 as the printer isused to print one or more parts. The block 632 establishes a common zheight for the calibration event aligned with the x-y print plane. Thetip 25 of the print head 24 is then raised and moved over the sensor 622such that the sensor 622 maps to determine an orientation and/orpositioning errors of the tip 25.

As discussed, in some embodiments, while the nozzle 25 is positionedwithin the heated build chamber, the x-y gantry can be used to move theprint head through x and y directions of a toolpath during printing,while the local Z positioner moves the print head comparatively smallerdistances (for example 0.03 inches) in the z direction while extrudingmaterial, to provide a toolpath that varies in not only the x, y butalso in the z direction. Accurate movement capability in z duringextrusion enables planned variable height toolpaths within a layer. Thisalso allows for “Z weaving”, formation of overlapped scarfed jointseams, and other part strengthening techniques to be employed. Forexample, FIG. 20 illustrates portions of a part on a build surface 558formed from extruded material using a print head controlled to printalong a toolpath including a z component, referred to herein as Zweaving. By moving the print head a short distance in the z directionduring printing, a layer 554 of material can be deposited on and betweenportions 552 of a previous layer to form interlocked joints 556, insteadof relying upon butt joints and discrete z single-height layers. Thisincreases the strength of the joints and the part. In addition tointra-layer z-height variation, the local z movement of the print headcan likewise be used for inter-layer printing, for example, Z weavingbetween adjacent layers resulting in increased part strength along thez-axis.

FIG. 21 is a diagrammatic illustration of another interlocked joint, inthe form of a scarf seam or scarf joint 600 between layers or extrusions602 and 604, which can be created with the ability to move the printhead in the z direction while extruding material as can be accomplishedusing disclosed local Z positioners. FIG. 22 provides anotherillustration, in an exploded perspective view, of formation of a scarfjoint 650 between layers 652 and 654. In this example, the scarf jointextrusion placement for printing the joint portion of layer 652 startsat around 30% of the slice height of the first printed layer 654—forexample at about 0.003” above the previous layer (not shown) for a0.010” slice (of layer 654). The pumps of the printer can be startedwith a pre-pump of extrusion material, then the xy gantry and local Zpositioner are controlled to start xy and z direction motionsimultaneously. The local Z positioner moves the print head up untilextruding has reached the full slice height (at an angle between 35degrees and 50 degrees from horizontal). Finally, the seam is closed byfinishing the seam without moving the print head in the z direction.Seam closing can also utilize tuning of the pump rollback volume.

Referring to FIG. 23 , a 3D printer is illustrated at 710 that includeslocal Z linear motors 717A, 717B for moving print heads 718A and 718B inthe z direct independently of each other. As illustrated, the 3D printer710 has a substantially horizontal xy print plane where the part beingprinted in indexed in a substantially vertical z direction as the partis printed in a layer by layer manner using the two print heads 718A,718B. The illustrated 3D printer 710 uses two consumable assemblies 712that retains a supply of a consumable filament for printing with system10. In some embodiments, each consumable assembly 712 is an easilyloadable, removable, and replaceable container device. Typically, one ofthe consumable assemblies 712 contains a part material filament, and theother consumable assembly 712 contains a support material filament, eachsupplying filament to one print head 718A or 718B.

Each print head 718A and 18B includes a housing that retains a liquefierassembly 720 having a nozzle tip 714. Each print head 718A and 718B isconfigured to receive a consumable material, melt the material inliquefier assembly 20 to product a molten material, and deposit themolten material from a nozzle tip 714 of liquefier assembly 720.

Guide tube 716 interconnects consumable assembly 712 and print head 718Aor 718B, where a drive mechanism of print head 718A or 718B (or of 3Dprinter 710) draws successive segments of the consumable filament fromconsumable assembly 712, through guide tube 716, to liquefier assembly720 of print head 718A or 718B. During a build operation, the successivesegments of consumable filament that are driven into print head 718A or718B are heated and melt in liquefier assembly 720. The melted materialis extruded through nozzle tip 714 in a layerwise pattern to produceprinted parts.

Exemplary 3D printer 710 prints parts or models and correspondingsupport structures (e.g., 3D part 722 and support structure 724) fromthe part and support material filaments, respectively, of consumableassemblies 712, using a layer-based, additive manufacturing technique.Suitable 3D printers 10 include fused deposition modeling systemsdeveloped by Stratasys, Inc., Eden Prairie, MN under the trademark“FDM”.

As shown, the 3D printer 710 includes system casing 726, chamber 728,platen 730, platen gantry 732, head carriage 734, and head gantry 736.System casing 726 is a structural component of 3D printer 710 and mayinclude multiple structural sub-components such as support frames,housing walls, and the like. In some embodiments, system casing 726 mayinclude container bays configured to receive consumable assemblies 712.In alternative embodiments, the container bays may be omitted to reducethe overall footprint of 3D printer 710. In these embodiments,consumable assembly 712 may stand proximate to system casing 726, whileproviding sufficient ranges of movement for guide tubes 716 and printheads 718A and 718B that are shown schematically in FIG. 22 .

Chamber 728 is an enclosed environment that contains platen 730 forprinting 3D part 722 and support structure 724. Chamber 728 may beheated (e.g., with circulating heated air) to reduce the rate at whichthe part and support materials solidify after being extruded anddeposited (e.g., to reduce distortions and curling). In alternativeembodiments, chamber 728 may be omitted and/or replaced with differenttypes of build environments. For example, 3D part 722 and supportstructure 724 may be built in a build environment that is open toambient conditions or may be enclosed with alternative structures (e.g.,flexible curtains).

Platen 730 is a platform on which 3D part 722 and support structure 724are printed in a layer-by-layer manner, and is supported by platengantry 732. In some embodiments, platen 730 may engage and support abuild substrate, which may be a tray substrate as disclosed in Dunn etal., U.S. Pat. No. 7,127,309, fabricated from plastic, corrugatedcardboard, or other suitable material, and may also include a flexiblepolymeric film or liner, painter’s tape, polyimide tape (e.g., under thetrademark KAPTON from E.I. du Pont de Nemours and Company, Wilmington,DE), or other disposable fabrication for adhering deposited materialonto the platen 730 or onto the build substrate. Platen gantry 732 is agantry assembly configured to move platen 730 along (or substantiallyalong) the vertical z-axis.

Head gantry 736 carries the local Z linear motors 717A and 717B retainseach print head 718A and 178B in a manner that prevents or restrictsmovement of the print head 18 relative to head carriage 736 so thatnozzle tip 714 remains in the x-y build plane, but allows nozzle tip 714of the print head 718A and 718B to be independently and controllablymoved into and out of the x-y build plane through movement of local Zlinear motors 717A and/or 7171B.

In the shown embodiment, head gantry 736 is a robotic mechanismconfigured to move the local Z linear motors 717A and 717B and theretained print heads 718A and 718B in (or substantially in) a horizontalx-y plane above platen 730. Examples of suitable gantry assemblies forhead gantry 736 include those disclosed in Swanson et al., U.S. Pat. No.6,722,872; and Comb et al., U.S. Pat. No. 9,108,360, where head gantry36 may also support deformable baffles (not shown) that define a ceilingfor chamber 728. Head gantry 736 may utilize any suitable bridge-typegantry or robotic mechanism for moving the local Z linear motors 717Aand 717B and the retained print heads 718A and 718B, such as with one ormore motors (e.g., stepper motors and encoded DC motors), gears,pulleys, belts, screws, robotic arms, and the like.

3D printer 710 also includes controller assembly 738, which may includeone or more control circuits (e.g., controller 740) and/or one or morehost computers (e.g., computer 742) configured to monitor and operatethe components of 3D printer 710. For example, one or more of thecontrol functions performed by controller assembly 738, such asperforming move compiler functions, can be implemented in hardware,software, firmware, and the like, or a combination thereof; and mayinclude computer-based hardware, such as data storage devices,processors, memory modules, and the like, which may be external and/orinternal to system 710.

Controller assembly 38 may communicate over communication line 744 withprint heads 718A and 718B, chamber 728 (e.g., with a heating unit forchamber 728), the local Z linear motors 717A and 717B, motors for platengantry 732 and head gantry 736, and various sensors, calibrationdevices, display devices, and/or user input devices. In someembodiments, controller assembly 738 may also communicate with one ormore of platen 730, platen gantry 732, head gantry 736, and any othersuitable component of 3D printer 710. While illustrated as a singlesignal line, communication line 744 may include one or more electrical,optical, and/or wireless signal lines, which may be external and/orinternal to 3D printer 710, allowing controller assembly 38 tocommunicate with various components of 3D printer 710.

During operation, controller assembly 738 may direct platen gantry 732to move platen 730 to a predetermined height within chamber 728.Controller assembly 738 may then direct head gantry 36 to move the localZ linear motors 717A and 717B and the retained print heads 718A and 718Baround in the horizontal x-y plane above chamber 28 and to move theprint heads 718A and 718B into and out of the x-y plane by manipulatingthe local Z linear motors 717A and 717B, wherein roads of material canbe extruded in the x-y plane or in three dimensions, as illustrated inFIGS. 16-18 . Controller assembly 738 may also direct print heads 718Aand 718B to selectively draw successive segments of the consumablefilaments from consumable assembly 712 and through guide tubes 716,respectively to print the part 722 and the support structure 744 in alayer-by-layer manner.

As discussed, embodiments providing a local Z positioner with a linear zmotor, allows the disclosed 3D printers to toggle between use of thelocal Z positioner to implement precision toolpaths including zdirection printing with a small range (e.g., moving the print head inthe z direction in small increments such as approximately 0.0005 inchesor approximately 0.030 inches) of z direction motion whilesimultaneously using the x-y gantry to move the print head in the x andy directions during some portions of the tool path, and using the localZ positioner as part of a tool changing system with the print headsstored in a tool bin outside of the heated print chamber and thusrequiring a larger range of motion (e.g., approximately 8.5 inches).Having both the local z printing movement as well as the tool changingmovement enabled by the same movement device results in a high level oflocation target accuracy, even when switching out one print head withanother in the middle of a part build. Knowledge of accurate tipposition is essential in order to build an accurate part, especiallywhen switching between two or more print heads during a build; with avariety of print head lengths/heights, as well as tip styles and typesfor different material extrusion requirements, the use of a local Zpositioner maintains the required tip position accuracy even whileentering and exiting the build chamber. For example, a following errorof less than 12 um has been observed while moving, with less than 2 umfollowing error after the local Z positioner comes to rest. The local Zpositioner provides other advantages as well, such as increasingglue-less speed due to reduced glue-less move times, as well as enablingin-situ monitoring and correction of layers experiencing overfill anddeformation from part curling or tip contamination layer depositionerrors. For example, inclusion of the local Z positioner allows thedisclosed controllers and computer systems to control print headmovement to toggle between multiple toolpaths to increase print speed orfor other reasons. Using the local Z positioner to move the print headin the local z direction at high accelerations, while simultaneouslymoving in xy and maintaining fidelity with low to zero hysteresis,allows disclosed 3D printers to spiral fill, create scarf joint seams,establish near true 3D printing (e.g., 2.75D printing) benefits likecreating smoother top surfaces, and utilize Z-weaving toolpaths.

Further, the disclosed 3D printers can utilize the local Z positioner toprint multiple z layers without moving the primary z or platen using theplaten gantry. For example, in some embodiments, layers over a zdirection band of approximately 0.25 inches can be printed whileextruding and moving in the z direction with the local Z positionerbefore moving the primary z gantry or platen. This can in turn extendthe life for the primary z gantry and related components by a factor of50 to 500.

Disclosed 3D printers, utilizing a linear motor driven local Zpositioner, provide numerous other benefits as well. Low force backdrivability of the linear motor, along with a µm linear encoder make thelocal positioner driven print head an ideal probe style sensor with theability to sense contact of the nozzle tip against a surface. Examplesinclude using the nozzle tip to touch off the platen for platen levelingand platen z zero homing, using the nozzle tip to touch off the part fortop of part detection, etc. If desired, disclosed 3D printers can alsobe configured to measure following error on the local Z linear motor(with lower P gains) to thereby measure upward force on the nozzle tip.This allows measurement of overfill or curl of parts.

Another advantage which can be achieved in some embodiments using thelower P gains provided by the local Z positioner is that the ability tohave the nozzle tip move up when a vertical force is applied. Oneprimary example is during tip wiping/brushing. Conventionally, the tipwipes need to be accurately located since the tips are very rigid in thez direction. With a linear motor, the P gains can be lowered in the zdirection so that the tip cover rides on top of the brush with aprescribed amount of z force to clean the tip. This allows a clean tipto be achieved without as fine of positioning as conventionallyrequired. Lower gains on the local Z positioner can also be beneficialduring tool change to allow for some compliance when the tool changemaster and slave are not at exactly the same height during lock andunlock.

Another advantage of the local Z positioner is the ability to compensatefor thermal expansion of the extruder portion of the print head as theextruder portion is heated to operating temperatures after the extruderis positioned within the heated chamber from the unheated tool chamber.Depending upon the extruder design, the extrusion temperature and theheated chamber temperature, the extruder can thermally expand asufficient amount to adversely affect the printing accuracy. By way ofexample, an extruder can thermally expand in the range of about 0.005inches and about 0.002 inches. The thermal expansion is exponential innature, meaning as the temperature extruder increases, the thermalexpansion increases in a non-linear fashion. The local Z positioner withthe linear motor provides sufficient resolution to retain the tip end ofthe extruder in the print plane as the extruder expands as it is heatedto an operating temperature.

While the time in which a length of the extruder reaches a steady stateis dependent on the extruder design, the extruder operating temperatureand the heated chamber temperature, an extruder in the presentdisclosure reaches a steady state in length in about five minutes withan exponential time constant of about seventy-five seconds. Whenfrequently changing from one print head to another using the toolchanger, it is important to preheat the unutilized print heads in theirtool crib positions, or the print activities will be significantlydelayed while waiting for heat up activities. Knowing that individualprint heads vary slightly in their overall dimensions (and thus theirexact tip location relative to a previously used tip within the printhead carriage), it is important to compensate for thermal expansion ofeach tip with respect to its positional tip location, while having aknowledge of its temperature. While the print heads are heated in thetool crib or rack, they have a particular temperature setpoint tomaintain, and thus have a particular length, width and overall size.When inserted into the heated printing chamber, they heat even furtheras they equilibrate to the heated chamber temperature, and can expandeven further. A precise knowledge of the expanded size is useful toprint accurate parts with a particular print head, whether only oneprint head is used throughout a build, or whether a variety of printheads are interchanged during a particular part build.

The present disclosure defines a plurality of parameters for eachextruder that are material, and therefore, temperature dependent.Exemplary parameters include expansion offset or thermal expansion andthe thermal expansion time constant which can be divided into aplurality different time constant values over a plurality of timeintervals, due to the exponential nature of the thermal expansion as thetemperature rises. These parameters are entered into an empiricalexponential equation that models the print head thermal expansion sizeversus temperature. For the disclosed extruder, the expansion offsetranges from about 0.0005 inches to about 0.002 inches depending on theoperating temperature, which is material specific, and the expansiontime constant is varied at about fifty second to about ninety secondintervals. This variation, if not accommodated for, can significantlyaffect the intended extruded layer positioning and intended extrudedlayer height.

In operation, a timer is started when the extruder tip is positionedinto the heated chamber. The local Z positioner is actuated to move theprint head based upon the exponential equation using the two parametersevery cycle such as, but not limited to a 1.000 Hertz update rate. Asthe linear motor of the local Z positioner can be moved in micronincrements, the linear motor of the local Z positioner will graduallymove the print head upward over the selected time frame or timeconstants to maintain the extruder tip in the selected z position whilethe extruder thermally expands.

In some instances, a tool or print head is returned to service prior toreaching a stabilizing temperature in the tool chamber while positionedin the tool rack. In this instance, only utilizing the expansion offsetand the thermal expansion time constant, which assumes a lower steadystate temperature would over compensate. To compensate for the potentialof returning a tool or print head to service prior to reaching a steadystate in the tool chamber, another exponential function can be startedas soon as the tool is removed from the heated chamber and placed intothe tool rack in the tool chamber to determine the contraction of thetool or print head as it cools. By way of example, the same parameterfor the maximum expansion offset would be utilized, but instead ofhaving an exponentially increasing unction, the offset wouldexponentially decrease such that at time zero, the expansion offsetwould zero out after the same number of contraction time constants asused for the thermal expansion time constant.

As disclosed above, an open loop control scheme can be utilized where anempirical exponential equation can be utilized based upon the thermalexpansion offset and the thermal expansion time constant. However, aclosed loop control scheme can also be utilized there a thermocouple isadded to the backbone of the extruder so that the mathematical model canbe generated that directly changes the local Z position based on theactual backbone.

Referring to FIGS. 24 and 25 , the tool connector 490 of the local Zpositioner 72 is illustrated in a lowered position and a raisedposition, respectively. Referring the FIG. 24 , the tool connector 490of the local Z positioner 72 is illustrated in the lowered position andengaging compression springs 452. The compression springs 452 engage thetool connector 490 proximate edges 490 to maintain substantially equalspring forces on opposite sides of the tool connect 490, which aids inpreventing the tool connector 490 from becoming misaligned. Further, thecompression springs 452 limit hysteresis or other undesirablepositioning errors as the parts are printed, as a typical printingposition of the print head 24 is in the lowered position.

Referring to FIG. 25 , the tool connector 490 is raised on the local Zpositioner 72 to its upper most raised position. In this raisedposition, the tool connector 490 is proximate the bumper 450. The bumper450 provide a cushioned positive stop that prevents the tool connector490 from be raised above an upper limit of the local Z positioner 72. Inthe event the tool connector 490 does contact the bumper 450 whichprovides a cushion to lessen the impact while retaining the toolconnector 490 to the local Z positioner 72. Lessing the impact of thetool connector 490 with the local Z positioner 72 aids in keeping thelocal Z positioner 72 in operation while also aiding in maintainingreliability of the local Z positioner 72.

Although the present disclosure may have been described with referenceto preferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the disclosure.

1. A method of moving a print head between a plurality of partitionedchambers in a 3D printer, the method comprising: providing the 3Dprinter having a thermal barrier having an area defined by a length andwidth, wherein a print head nozzle can be positioned through the thermalbarrier along the width or the length and at least two partitionedchambers below the area of the thermal barrier, wherein a first chambercomprises a printing chamber and a second chamber comprises a chamberproviding another functionality; raising the print head in a z directionfrom the second chamber to above the thermal barrier; moving the printhead in a x-y direction from above the second chamber over the partitionto a location above the first chamber; and lowering the print head inthe z direction and into the first chamber such that an extrusion portof a nozzle of the print head is proximate a x-y print plane.
 2. Themethod of claim 1, wherein the second chamber comprises a calibrationchamber with a sensor configured to determine a location of the nozzleon the print head in x, y and z to determine location errors of thenozzle.
 3. The method of claim 1, and further comprising activelycooling the second chamber.
 4. The method of claim 1, and furthercomprising actively heating the first chamber.
 5. The method of claim 1,wherein the at least two chambers comprise a third chamber.
 6. A methodof moving a print head between a plurality of partitioned chambers in a3D printer, the method comprising: providing the 3D printer having aprint head movable in x, y and z directions and at least two partitionedchambers below a movement envelop of the print head, wherein a firstchamber comprises a printing chamber and a second chamber comprises achamber providing another functionality; raising the print head in a zdirection from within the second chamber to above the second chamber;moving the print head in a x-y direction from above the second chamberover the partition to a location above the first chamber; and loweringthe print head in the z direction and into the first chamber such thatan extrusion port of a nozzle of the print head is proximate a x-y printplane.
 7. The method of claim 6, wherein the 3D printer comprises athermal barrier above the at least two chambers, wherein the print headis movable in the z direction through the thermal barrier such that theprint head is movable into and out of the at least two chambers.
 8. Themethod of claim 6, wherein the second chamber comprises a calibrationchamber with a sensor configured to determine a location of the nozzleon the print head in x, y and z to determine location errors of thenozzle.
 9. The method of claim 8, wherein the at least two chamberscomprise a third chamber.
 10. The method of claim 6, and furthercomprising actively cooling the second chamber.
 11. The method of claim6, and further comprising actively heating the first chamber.
 12. Amethod of moving a print head between a plurality of partitionedchambers in a 3D printer, the method comprising: providing the 3Dprinter having a thermal barrier having an area defined by a length andwidth, wherein a print head nozzle can be positioned through the thermalbarrier along the width or the length and at least two partitionedchambers below the area of the thermal barrier, wherein a first chambercomprises a printing chamber and a second chamber comprises acalibration chamber having a calibration chamber with a sensor; movingthe nozzle above the sensor to determine a location of the nozzle on theprint head in x, y and z to determine location errors of the nozzle;raising the print head in a z direction from the second chamber to abovethe thermal barrier; moving the print head in a x-y direction from abovethe second chamber over the partition to a location above the firstchamber; and lowering the print head in the z direction and into thefirst chamber such that an extrusion port of a nozzle of the print headis proximate a x-y print plane.
 13. The method of claim 12, and furthercomprising actively heating the first chamber.
 14. The method of claim12, and further comprising actively cooling the second chamber.
 15. Themethod of claim 12, wherein the second chamber houses a calibrationsensor wherein the calibration sensor is utilized to determine alocation of the print head nozzle.